Charger with compact structure

Abstract

The utility model discloses a charger with a compact structure, which relates to the technical field of chargers and comprises a charger shell and an AC-DC main circuit, and the AC-DC main circuit comprises an AC input pin, a DC output interface, a PCB (printed circuit board) and a current fuse RF1. The charger shell comprises a front-end shell and a rear-end shell; the AC input pin comprises a plugging part and a power connection part; the L-line input pin and the N-line input pin are arranged at an interval left and right, so that an accommodating space is formed between the power connection part of the L-line input pin and the power connection part of the N-line input pin at an interval; the current fuse RF1 is horizontally connected to the PCB and located in the accommodating space, and one end of the current fuse RF1 is electrically connected with the L line input pin; on one hand, the structure of the charger is more compact, the miniaturization design of the charger is more facilitated, on the other hand, the current fuse RF1 can be closer to the AC input pins, and when circuit connection is designed, the circuit connection distance between the current fuse RF1 and the corresponding AC input pins is more facilitated to be shortened.

Description

Technical Field

[0001] This utility model relates to the field of charger technology, and in particular to a compact charger. Background Technology

[0002] The structure of European standard two-prong charging plugs is often shown in the Chinese utility model "A Waterproof European Standard Power Charger" (announcement number CN211958797U). The charger's outer casing has a flat front shell with corresponding diamond-shaped sections on both sides. The two prongs of the charger are connected to the front of the flat front shell for use with European standard sockets. With the steady growth in the charger market demand, developing a more compact and smaller charger is particularly important. Utility Model Content

[0003] To overcome the shortcomings mentioned above, this utility model aims to provide a technical solution to address the aforementioned problems.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a compact charger, including a charger housing and an AC-DC main circuit, wherein the AC-DC main circuit includes an AC input pin, a DC output interface, a PCB board and a current fuse RF1;

[0005] The charger housing includes a front housing for connecting to an AC input plug, and a rear housing connected to the front housing; the front housing has an internal space, the rear housing has an internal space, and the internal spaces of the front housing and the rear housing are connected front to back.

[0006] The PCB board is located inside the rear housing and extends forward to penetrate the front housing.

[0007] The AC input pins include a plug portion located outside the front housing and a power receiving portion located inside the front housing;

[0008] The device has two AC input pins, namely an L-line input pin and an N-line input pin. The L-line input pin and the N-line input pin are arranged side by side, forming a space between the contact parts of the L-line input pin and the contact parts of the N-line input pin.

[0009] The current fuse RF1 is horizontally connected to the PCB board and located in the housing space. One end of the current fuse RF1 is electrically connected to the L line input pin.

[0010] As a further embodiment of this utility model: the length direction of the main body of the current fuse RF1 is the left-right direction;

[0011] Both ends of the main body of the current fuse RF1 are at least partially located in the receiving space along its length.

[0012] As a further embodiment of this utility model, the AC-DC main circuit also includes an inductor L1, an electrolytic capacitor EC1, and an electrolytic capacitor EC2 connected to the PCB board. The positive terminals of the electrolytic capacitor EC1 and EC2 are electrically connected to the two ends of the inductor L1, respectively.

[0013] As a further embodiment of this utility model: the inductor L1, electrolytic capacitor EC1, and electrolytic capacitor EC2 are all horizontally connected to the PCB board and are at least partially located inside the front housing.

[0014] As a further embodiment of this utility model: the front end housing is configured as a flat structure, and the direction corresponding to the flat distance is the same as the thickness direction of the PCB board.

[0015] As a further embodiment of this utility model: electrolytic capacitor EC1, electrolytic capacitor EC2, and inductor L1 are connected to the PCB board and form a structure.

[0016] The length direction of the main body of electrolytic capacitor EC1 is the same as that of the main body of electrolytic capacitor EC2, and the length direction of the main body of inductor L1 is perpendicular to the length direction of the main body of electrolytic capacitor EC1.

[0017] The positive terminals of electrolytic capacitor EC1 and electrolytic capacitor EC2 are located on the same side of inductor L1 and are close to both ends of inductor L1.

[0018] As a further embodiment of this utility model: the AC-DC main circuit also includes a transformer T1;

[0019] Transformer T1 is connected to the PCB board, and an integrally molded Mylar insulating film is placed between the primary winding and the secondary winding of transformer T1.

[0020] As a further aspect of this invention, the AC-DC main circuit uses DIP components.

[0021] As a further embodiment of this utility model: the rear housing includes a main body integrally formed with the front housing, the main body being connected front and rear, and the rear housing also includes a rear cover covering the rear opening of the main body, with the connection opening disposed on the rear cover.

[0022] As a further embodiment of this utility model: the front end housing is connected to the AC input pin by injection molding.

[0023] Compared with the prior art, the beneficial effects of this technical solution are as follows: On the one hand, the space occupied by the power-on parts of the L-line input pin and the N-line input pin can be used to house the current fuse RF1, making the charger structure more compact and facilitating the miniaturization design of the charger. On the other hand, by utilizing the space between the power-on parts of the L-line input pin and the N-line input pin, the current fuse RF1 can be placed closer to the AC input pin, which makes it easier to shorten the line connection distance between the current fuse RF1 and the corresponding AC input pin when designing the circuit connection.

[0024] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a three-dimensional structural view of the present invention;

[0027] Figure 2 This is a schematic diagram of the internal structure of this utility model. The inductor L1 is completely located inside the front housing, the electrolytic capacitor EC1 is completely located inside the front housing, and the electrolytic capacitor EC2 is completely located inside the front housing.

[0028] Figure 3 This is another three-dimensional view of the structure of this utility model;

[0029] Figure 4 This is another internal structure diagram of the present invention. The inductor L1 is completely located inside the front housing, the electrolytic capacitor EC1 is completely located inside the front housing, and the electrolytic capacitor EC2 is partially located inside the front housing.

[0030] Figure 5 This is the circuit schematic diagram of this utility model. Detailed Implementation

[0031] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0032] Please see Figure 1-5 A compact charger includes a charger housing 1 and an AC-DC main circuit.

[0033] The AC-DC main circuit includes AC input pin 2, DC output interface 3, PCB board 4, and current fuse RF1.

[0034] In some embodiments, the charger housing 1 includes a front housing 101 for connection to an AC input pin 2, and the charger housing 1 also includes a rear housing 102 connected to the front housing 101.

[0035] The front housing 101 has an internal space, the rear housing 102 has an internal space, and the internal spaces of the front housing 101 and the rear housing 102 are connected front to back, that is, the PCB board 4 can be set in the rear housing 101 and extend forward to penetrate into the front housing 101.

[0036] In some embodiments, the AC input pin 2 is connected to the front end of the front housing 101.

[0037] In some embodiments, the DC output interface 3 is disposed inside the rear housing 102, and a connection opening corresponding to the DC output interface 102 is provided on the outer side of the rear housing 102.

[0038] In some embodiments, the connection opening is provided on the rear side of the rear housing 102.

[0039] In some embodiments, the rear housing 102 includes a main body 1021 integrally formed with the front housing 101, the main body 1021 being connected front and rear, and the rear housing 102 also includes a rear cover 1022 covering the rear opening of the main body 1021, with a connection opening provided on the rear cover 1022.

[0040] That is, the PCB board 4 can be inserted into the rear housing 102 through the rear opening of the charger housing, and through the front-end housing 101 and the rear housing 102 are connected, the PCB board 4 can continue to move forward so that a part of the PCB board 4 enters the front housing 101.

[0041] In some embodiments, the front housing 101 is formed on the AC input pin 2 by means of, for example, injection molding or injection molding.

[0042] AC input pin 2 includes a plug portion 201 located outside the front housing 101, a connection portion 202 that contacts the front housing 101, and a power receiving portion 203 located inside the front housing 101.

[0043] In some embodiments, the AC input pin 2 has two pins, namely L-line input pin 2a and N-line input pin 2b. The L-line input pin 2a and the N-line input pin 2b are arranged with a left-right interval, so that the contact part of the L-line input pin 2a and the contact part of the N-line input pin 2b are separated to form a receiving space 204.

[0044] The current fuse RF1 is horizontally connected to the PCB board 4 and located in the housing space 204.

[0045] On the one hand, the space occupied by the energizing parts of the L-line input pin 2a and the N-line input pin 2b can be used to house the current fuse RF1 in the receiving space 204, making the charger structure more compact and facilitating the miniaturization design of the charger. On the other hand, by utilizing the receiving space 204 between the energizing parts of the L-line input pin 2a and the N-line input pin 2b, the current fuse RF1 can be placed closer to the AC input pin, which makes it easier to shorten the line connection distance between the current fuse RF1 and the corresponding AC input pin when designing the circuit connection.

[0046] like Figure 5 As shown, one end of the current fuse RF1 is electrically connected to the L-line input pin.

[0047] In some embodiments, a horizontal connection means that the pins of the current fuse RF1 are connected to the PCB board 4, and the length direction of the main body of the current fuse RF1 is parallel or nearly parallel to the soldering surface on the PCB board 4.

[0048] The main body of the current fuse RF1, excluding the pins, is typically arranged in a columnar shape.

[0049] In some embodiments, the length direction of the main body of the current fuse RF1 is left-right, and both ends of the main body of the current fuse RF1 are at least partially located in the receiving space 204.

[0050] In some embodiments, after the PCB board 4 penetrates the front housing 101, it can extend forward to the area where the power connection part is located, so that the current fuse RF1 can be connected to the PCB board more conveniently, and the power connection part can be connected to the corresponding connector on the PCB board 4 more conveniently.

[0051] In some embodiments, the AC-DC main circuit further includes an inductor L1, an electrolytic capacitor EC1, and an electrolytic capacitor EC2 connected to the PCB board 4, with the positive terminals of the electrolytic capacitor EC1 and EC2 respectively electrically connected to the two ends of the inductor L1.

[0052] In some embodiments, the inductor L1, electrolytic capacitor EC1, and electrolytic capacitor EC2 are all horizontally connected to the PCB board 4 and are at least partially located within the front housing 101.

[0053] By configuring the current fuse RF1, the space occupied by the current fuse RF1 outside the accommodating space inside the front housing 101 can be reduced, thereby reserving more space (space outside the accommodating space inside the front housing) for the larger electrolytic capacitors EC1 and EC2. The lateral distance of the larger space is not limited by the connection parts of the L-line input pin and the N-line input pin, so that the larger (e.g., longer) electrolytic capacitors EC1 and EC2 can have more space to be installed in the flat front housing described below.

[0054] In some embodiments, a horizontal connection means that the pins of inductor L1, electrolytic capacitor EC1, and electrolytic capacitor EC2 are connected to the PCB board, and the main length direction of inductor L1, electrolytic capacitor EC1, and electrolytic capacitor EC2 are parallel or nearly parallel to the soldering surface on the PCB board.

[0055] The main body of inductor L1, excluding the pins, is typically arranged in a columnar shape.

[0056] The main body of an electrolytic capacitor EC1, excluding the pins, is typically arranged in a columnar shape.

[0057] The main body of the electrolytic capacitor EC2, excluding the pins, is typically arranged in a columnar shape.

[0058] For example, the main body of inductor L1 is partially or completely located inside the front housing 101, the main body of electrolytic capacitor EC1 is partially or completely located inside the front housing 101, and the main body of electrolytic capacitor EC2 is partially or completely located inside the front housing 101.

[0059] In some embodiments, the front housing 101 is configured as a flat structure, and the direction corresponding to the flat distance is the same as the thickness direction of the PCB board 4.

[0060] For example, if the charger is a European standard charger, the charger housing 1 can be a flat front housing with a diamond-shaped part (located on the left and right sides) that is a European standard two-prong charger housing.

[0061] In other words, when applied to this type of charger housing with a flat structure, the above-mentioned configuration can make the charger structure more compact, which helps to reduce the size of the charger. On the other hand, it allows electrolytic capacitors EC1 and EC2 to be placed more into the flat front shell. Due to the structural feature of the flat front shell with its upper and lower sides closer together, electrolytic capacitors EC1 and EC2 can have more side portions close to the upper or lower end surface of the flat front shell, and more side portions through the PCB board 4 close to the lower or upper end surface of the flat front shell 101, which makes the heat dissipation of electrolytic capacitors EC1 and EC2 better.

[0062] like Figure 2 As shown, in some embodiments, electrolytic capacitor EC1, electrolytic capacitor EC2, and inductor L1 are connected to PCB board 4 and are configured such that: the length direction of the main body of electrolytic capacitor EC1 is the same as the length direction of the main body of electrolytic capacitor EC2, and the length direction of the main body of inductor L1 is perpendicular to the length direction of the main body of electrolytic capacitor EC1; the positive terminals of electrolytic capacitor EC1 and electrolytic capacitor EC2 are both located on the positive terminal portions corresponding to the same orientation along the same length direction; the positive terminal portions of electrolytic capacitor EC1 and electrolytic capacitor EC2 are both located on the side of inductor L1 and are respectively close to the two ends of inductor L1.

[0063] In some embodiments, inductor L1 is a color-coded inductor.

[0064] In some embodiments, the AC-DC main circuit also includes a transformer T1.

[0065] In some embodiments, transformer T1 is connected to PCB board 4, and an integrally formed Mylar insulating film 5 is provided between the primary winding and the secondary winding of transformer T1, which can achieve the effect of pressure resistance and insulation.

[0066] In some embodiments, the AC-DC main circuit uses DIP components, which can be inserted using an automated insertion machine.

[0067] In some embodiments, the PCB board 4 can be installed into the rear housing 102 by using an automatic board mounting machine; after the PCB board 4 is installed, the rear cover 1022 can be installed using an automatic housing mounting machine; after the rear cover 1022 is installed, the rear cover 1022 and the main body 1021 can be welded using an automatic ultrasonic welding device.

[0068] After the welding is completed, an automatic laser labeling machine can be used for laser labeling, and an automatic aging chamber can be used for aging testing.

[0069] The structural design of this charger is suitable for automated production and assembly. It can be applied to current conventional automated production lines to achieve a large production capacity, currently reaching 2,500 units per hour.

[0070] In some embodiments, the AC-DC main circuit further includes a rectifier bridge BD1, a secondary output circuit, a power management chip U1 and its peripheral circuits, and the DC output interface is electrically connected to the secondary winding of the transformer T1 through the secondary output circuit.

[0071] In some embodiments, the DC output interface is, for example, a USB-A interface or a USB-C interface.

[0072] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A compact charger, comprising a charger housing and an AC-DC main circuit, characterized in that, The AC-DC main circuit includes an AC input pin, a DC output interface, a PCB board, and a current fuse RF1. The charger housing includes a front housing for connecting to an AC input plug, and a rear housing connected to the front housing; the front housing has an internal space, the rear housing has an internal space, and the internal spaces of the front housing and the rear housing are connected front to back. The PCB board is located inside the rear housing and extends forward to penetrate the front housing. The AC input pins include a plug portion located outside the front housing and a power receiving portion located inside the front housing; The device has two AC input pins, namely an L-line input pin and an N-line input pin. The L-line input pin and the N-line input pin are arranged side by side, forming a space between the contact parts of the L-line input pin and the contact parts of the N-line input pin. The current fuse RF1 is horizontally connected to the PCB board and located in the housing space. One end of the current fuse RF1 is electrically connected to the L line input pin.

2. The charger according to claim 1, characterized in that, The length of the main body of the current fuse RF1 is in the left-right direction; Both ends of the main body of the current fuse RF1 are at least partially located in the receiving space along its length.

3. The charger according to claim 2, characterized in that, The AC-DC main circuit also includes an inductor L1, an electrolytic capacitor EC1, and an electrolytic capacitor EC2 connected to the PCB board. The positive terminals of electrolytic capacitor EC1 and electrolytic capacitor EC2 are electrically connected to the two ends of inductor L1, respectively.

4. The charger according to claim 3, characterized in that, Inductor L1, electrolytic capacitor EC1, and electrolytic capacitor EC2 are all horizontally connected to the PCB board and are at least partially located inside the front housing.

5. The charger according to claim 4, characterized in that, The front shell has a flat structure, and the direction corresponding to the flat distance is the same as the thickness direction of the PCB board.

6. The charger according to claim 4 or 5, characterized in that, Electrolytic capacitor EC1, electrolytic capacitor EC2, and inductor L1 are connected on the PCB board and form a... The length direction of the main body of electrolytic capacitor EC1 is the same as that of the main body of electrolytic capacitor EC2, and the length direction of the main body of inductor L1 is perpendicular to the length direction of the main body of electrolytic capacitor EC1. The positive terminals of electrolytic capacitor EC1 and electrolytic capacitor EC2 are located on the same side of inductor L1 and are close to both ends of inductor L1.

7. The charger according to claim 1, characterized in that, The AC-DC main circuit also includes transformer T1; Transformer T1 is connected to the PCB board, and an integrally molded Mylar insulating film is placed between the primary winding and the secondary winding of transformer T1.

8. The charger according to claim 1, characterized in that, The AC-DC main circuit uses DIP components.

9. The charger according to claim 1 or 8, characterized in that, The rear housing includes a main body integrally formed with the front housing, the main body being connected front and rear. The rear housing also includes a rear cover covering the rear opening of the main body, with the connection opening located on the rear cover.

10. The charger according to claim 1, characterized in that, The front housing is connected to the AC input pin using injection molding.

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